Miller Electric Big 40 CAT manual Control Box Assembly − CC/CV Models

Page 80

Item

Dia.

 

Part

Description

Quantity

No.

Mkgs.

 

No.

 

 

Figure 13-2. Control Box Assembly − CC Models (Continued)

 

 

 

 

 

 

 

. . . . . . . . .

. . . . . . .

. . .

190 260 . .

HARNESS, unit weld control (consisting of)

. . . 1

. . . . . . . . .

. PLG3

. . .

. 158465 . . .

. CONN, rect univ 084 12p/s 3row plug cable lkg

. . . 1

. . . . . . . . .

. . . . . . .

. . .

. 187654 . . .

. SEAL, wire univ 12p/s 3row

. . . 1

. . . . . . . . .

. PLG6

. . .

. 114063 . . .

. CONN, rect univ 084 4p/s 1row plug cable lkg

. . . 1

. . . . . . . . .

. . . . . . .

. . .

. 192309 . . .

. CLIP, snap in .630 bundle .250 hole .248 thk

. . . 2

. . . 12 . . .

. . . . . . .

. . .

177 136 . .

CLAMP, capacitor 1.375dia

. . . 1

. . . 13 . . .

. . C9 .

. . .

. 087 110 . .

CAPACITOR, elctlt 240uf 200VDC

. . . 1

. . . 14 . . .

. . R6 .

. . .

141 424 . .

RESISTOR, ww fxd 30 w 25 ohm faston te

. . . 1

. . . 15 . . .

. PC7

. . ♦195 706 . .

MODULE, pull to idle, two output, 7 pin

. . . 1

. . . 16 . . .

. CR4

. . ♦113 247 . .

RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg

. . . 1

. . . 17 . . .

. CR6 . .

♦090104 . .

RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg

. . . 1

. . . 18 . .

CR2, CR3 .

090 104 . .

RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg

. . . 2

. . . . . . . . .

. . . . . . .

. . .

212 452 . .

HARNESS, engine control (consisting of)

. . . 1

. . . 19 D10/C10, D11/C11 189 701 . . .

. DIODE/CAPACITOR BOARD

. . . 2

. . . 20 . . .

. . R8 .

. . .

217 335 . . .

. RESISTOR BOARD

. . . 1

. . . 21 . . .

. CB10

. . .

190 374 . . .

. CIRCUIT BREAKER, auto reset 12VDC 40A

. . . 1

. . . . . . . . .

. . . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . 2

. . . . . . . . .

. PLG4

. . .

. 114 062 . . .

. CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg

. . . 1

. . . 22 . . .

. CR1 . . .

214 876 . . .

. RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin

. . . 1

. . . 23 . . .

. CR9 . . .

090 104 . . .

. RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg

. . . 1

. . . 24 . . .

. CR8 . . .

155 309 . .

CONTACTOR, Solenoid 12vdc Continuous 400a Inrush

. . . 1

♦Optional

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

4

3

21

16

20

15

18

17

2

11

19

1

 

 

 

 

 

22

12

 

5

 

 

13

10

14

6 7

8

9

802 360

Figure 13-3. Control Box Assembly − CC/CV Models

OM-4406 Page 74

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Contents Description OM-4406Processes From Miller to You Table of Contents − Maintenance & Troubleshooting Deccon111/02 DirectivesStandards Sound Level Information Deccon1sound11/02Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Definitions + − Starting InstructionsAre possible hazards as Can cause severe burns. DoFalling equipment can cause Serious injury and damageReturn To Table Of Contents Manufacturer’s Rating Labels For CE Products − 50 h StdStd CC Models CC/CV ModelsSymbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And OverheatingAC Generator Power Curve Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld LoadVolt-Ampere Curve For CC/CV Models In AC TIG Mode − Installation Installing Welding Generator See Sections 5-2AndLocation Grounding Airflow ClearanceUsing Lifting Eye Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceInstalling Exhaust Pipe Tools Needed 1/2Stop engine and let cool Point exhaust pipe in desired diActivating The Dry Charge Battery If Applicable Do not overfill battery cellsRead and follow all instruc ChargerConnect Negative − Cable Last Connecting The BatteryReinstall cover after connecting battery Coolant Recovery Tank Engine Prestart ChecksConnecting To Weld Output Terminals Selecting Weld Cable SizesConnecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Indicator Lights Do not switch under loadEngine Starting Controls To Start Do not use etherRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Set weld controls as shown toReturn To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionEngine Oil Pressure Light Use switch to select weld amperage rangeVoltage/Amperage Adjust Switch And Remote 14 Receptacle Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control Stick − Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt least once a month, run en Open, contact Factory AuthoClose panel opening if no connections are made to generator Three-Phase Power ConnectionRear Of Panel Circuit Breaker CB2 Circuit Breaker CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Every 8 hEvery 50 h Every 100 hService Every 1000 hEvery 2000 h Caterpillar Customer AssistanceServicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseTools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Adjusting Engine Speed Idle Speed AdjustmentWeld/Power Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic ChecksDiagnostic Checks While Running Start Engine With No Load AppliedTroubleshooting Welding − CC ModelsWelding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Wiring harness and components Shutdown switch is released OutTemperature is too high see Sections 5-7and Air in fuel system. See engine manual− Electrical Diagrams Circuit Diagram For CC Welding Generator215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B Welding Generator − RUN-IN ProcedureWetstacking Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not PerformRun-In Procedure Using Resistance Grid Bank/gridFrom flammables Do not perform run-in− Generator Power Guidelines Has this symbolSelecting Equipment Grounding Generator To Truck Or Trailer FrameGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated Electrical codesApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes113 108 100 CC only 119 110 109 111 -4 or − Parts List117 116 103 102 115 FIG 114 105 104 101 120 51 52 85 FigDia Part Description Quantity Dia Part Description Quantity Mkgs 095 Control Box Assembly − CC Models Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1Item Panel, Front w/Components − CC Models MS1 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1ItemPC6 192 PLG6 Hardware is common Not available unless listed 34 36 27 26Main Rectifier Assembly -1Item Main Rectifier Assembly Page Your distributor also gives SupportMiller Electric Mfg. Co For assistance in filing or settling claims, contactYour distributor and/or equipment manufacturer’s Transportation Department
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